Screw Compressors

Unrivalled versatility. These two words describe in a nutshell exactly what makes AERZEN screw compressors so special: the biggest range of models; the highest number of possible modifications and the widest range of accessories. But these stages and packaged unit series have a lot more going for them, not least the development capability of the global market leader, which has been continuously working on innovations, optimisation and completion of its successful compressors since 1943.

Freeing up potential.

For decades, leading packagers and industrial users have insisted upon AERZEN compressor stages and packaged units. Why? Because with their exceptional versatility these machines are the ideal solution for every application. Originally designed for compressing air, nitrogen and neutral gases, these all-round geniuses are also developing their strengths in use with special gases, in vacuum operation and in inlet pressure applications. Direct and belt-driven, dry running and classified oil-free to class 0 or with oil injection, with or without pre-inlet. Let’s put it this way: AERZEN has the right compressor for every application.

Screw compressors are perforce twin-shaft rotating lobe machines. They work on the positive displacement principle with internal compression and are so-called compulsive conveyors. This applies for all screw compressors. However, what makes AERZEN screw compressors special is that we have made reliability, ease of maintenance, user-friendliness, flexibility and energy efficiency a matter of principle. The result is a range of unique design features. Take the efficiency coefficients for example, such as the AERZEN 3+4 VML profile or the 4+6 VM profile. Compared to standard compressors they deliver an considerable energy saving. And what is the ultimate in compressor technology? That is AERZEN new E-compressors. With an increase in efficiency of around 6% they free up even more valuable potential.

Oil-free screw compressors meet your highest demands for the task

Oil-free compression processes are becoming more and more necessary in industry, medicine and food manufacturing, so that absolutely no foreign material is found. The ideal choice? Oil free screw compressors from AERZEN. Some work with a conventional piston or an oil-injected compressor because of the thermal dissipation where the oil offers a seal for those spaces in-between. However, for hygienically-critical tasks, working with oil-free compressors is highly recommended when supplied with a pressure filter. Here, you can be sure that no greasy residue will end up in the air flow. These are called oil-free systems. Screw compressors are basically rotor machines that are operated in two waves, compressing the air in the inner chamber. This concept is not new, but when talking about efficiency, reliability and maintenance-friendly equipment, AERZEN is in a class all its own.

Energy efficiency is becoming more important for screw compressors

Screw compressors are based on the rotary lobe compressor concept. These compress gas via the rotation of the interlocking rotor blades that are arranged in a spiral. Thus, the compression of the chamber is gradually reduced and the volume of gas compressed with the help of the lobes. The reliable production of pressurized air in power plants, and other industries, is necessary. Conventional compressors produce so much more noise than screw compressors. This lies in its functionality because the wear-and-tear in screw compressors is basically minimal. This results in robust, reliable and maintenance-friendly equipment for numerous applications. When thinking about equipment that are direct drive or belt-driven, the question for many companies is if they should switch to using screw compressors all together. The efficiency during compression is especially high – which means lower energy costs for you. In an age where energy prices are a very important aspect, thermal recycling also plays a large role nowadays.

The screw compressor that multi-tasks

The huge versatility and flexibility of screw compressors makes them ideal to use in so many areas. They are perfect and reliable in compressing air, nitrogen and other neutral gases, as well as other categorized gases. This oil-free option is especially suitable when other compressors can’t cut it. The working principle of the screw compressor provides a significant increase in energy efficiency and a higher performance compared to piston compressors. As technology improves, so does the efficiency with every generation of equipment. You’ll find uses for oil-free screw compressors where the highest standards of adaptability and durability are required. Here, transporting bulk goods and powder pneumatically is absolutely no problem because there are no contaminants or clumping like when using oil. Power plants and the chemical industry require a reliable system that supplies pure oxidized air. AERZEN’s screw compressors are the perfect choice here, too.

Fewer vibrations equals less noise

There are one and two-wave rotary lobe compressors, especially when talking about screw compressors that normally have two parallel rotary blades with different threading. These grab on to each other like teeth and compress the gas that is trapped between. When not using oil-free equipment, oil will be injected to cool and seal it. This procedure, called fluid cooling, is recommended when the operating conditions requires higher surrounding temperatures. Oil can also assist in minimizing the wear and tear in the equipment. Oil-free premium construction manages this without these measures and are, thanks to high-precision production methods and synchronized low-friction sprockets, absolutely sealed. A huge advantage of screw compressors is how quiet they are while in use. Unlike piston compressors, that have to be stopped in the middle. The vibrations inside the screw compressors are significantly reduced.

Less maintenance due to fewer moving parts

Screw compressors are extremely low-maintenance because there are fewer moving parts. Due to the missing oscillating power, the compression levels are less prone to cracking and other wear. Regarding efficiency of the compression, the screw compressor also has advantages because piston compressors lose approximately a tenth of the suctioned air via the piston rings. A screw compressor sees significantly less pressure loss and rarely exceeds a value of 0.1 – 0.2 percent. Considering the basic construction, screw compressions can pass for piston compressors and with unprecedented capabilities, thereby, allowing a strong reduction in energy costs and CO² emissions during use. There is further optimizing potential in the flow ratio of the pressurized air during the screw compressor’s processes. When needed, premium motors, with the highest energy efficiency, are available in order to meet the requirements of the current efficiency class. Here, future reliability is especially important for customers because the longevity determines whether or not the future challenges of the efficiency class can be met.

Perfect sound insulation by optimizing flow control

The energy efficiency of screw compressors can be optimized via various measures. Improvements in the air’s inflow in the power unit has been proven to be especially effective. In equipment in the newest Generation 5 plus from AERZEN, all of the components are aligned to provide optimal precision. Reducing pressure loss and improving the intake and outlet openings help the supply of the desired ultimate pressure remain stable and reliable. The additional insulation does not only reduce the noise level during use, but also optimizes the total flow conditions. By using an innovative insulation-geometry, the sound pressure levels sink. Moreover, it acts as an effective spark arrester. Equipment fitted with this feature are also approved for explosion-proof power plant grounds. In spite of the optimal insulation features, no additional material is needed for this insulation. There is no need to worry about contamination from damaged insulation material, etc. The corresponding maintenance costs are also omitted. In addition to the need of oil-free compressors, an effective insulation without the danger of any sort of contamination is one of the most important challenges in hygienically-sensitive areas such as the food industry and chemical plants. When needed, a compressed air filter can also be utilized to clean the used air. In medical fields, special filters like these to prepare the compressed air are common like a separation system or dryers for other residues. To avoid any unwanted moisture in the area of application, boosters and dryers ensure the effective removal of any signs of moisture present in the air. The fact that no grease, at any time, will end up in the chamber is guaranteed – which qualifies the new models as completely oil-free compressors.

Easy operation and flexible retrofitting possibilities

Comfortable operation of modern screw compressors is not a problem in today’s digital age. Operation and maintenance are easy and reduce further costs. The quiet belt drive of the equipment in Generation 5 plus makes it possible to install various belt pulleys to achieve the desired ratio. Making changes aren’t a problem, either. The compressor remains flexible to adjust to specific parameters and does not have to be replaced by a different model with inflexible settings. Maintenance is extremely low on the belt drive because the correct tension, via its own weight, is guaranteed. The speed of the equipment can also be electronically controlled. High precision and the exact consistency of the desired pressure is in most applications an absolute must. An integrated control panel can be found directly on the housing. By optimizing the placement of the control panels on the front of the equipment, you will save space by utilizing the “side-by-side” principle. A possible oil check during operation is also possible. Special AERZEN oils extend the changing interval twice as much as predetermined values.

Quality is the most important criterion

The high quality of AERZEN’s Premium Compressors is internationally recognized. Low operation costs of these modern screw compressors, while retaining their high value, go hand-in-hand with excellent reliability and durability while fulfilling the highest economic and environmental criteria.

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